2012-2013 Polaris Sportsman 400 H.O. / 500 Service Manual - All Models

2012–2013 Polaris Sportsman 400 and 500 Service Manual

• Covers 2012–2013 Polaris Sportsman 400 H.O. and 500 series, including Touring, Forest, and EFI Tractor variants
• Original OEM publication 9923792, copyright 2012 Polaris Sales Inc.
• Contains 438 pages with detailed engine exploded views, wiring schematics, and torque specification tables
• Delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• how factory workshop documentation is structured
• This edition is the primary factory reference for the 2012–2013 model year range, documenting both carbureted and EFI fuel systems across the 400 and 500 platform configurations.

Contents Overview

This 2012–2013 Polaris Sportsman 400 / 500 service manual provides technical documentation for engine maintenance, chassis diagnostics, and electrical system troubleshooting. Initial sections define vehicle identification, VIN decoding, and paint codes, followed by detailed periodic maintenance charts and lubricant product listings.

The core technical content includes cylinder head disassembly, valvetrain inspection, crankshaft straightening, and transmission repair sequences. Electrical references include alternator output ratings, circuit breaker specifications, and sensor values, while the drivetrain section covers gear ratios, front gearcase maintenance, and clutching setups for various altitudes.

Specification Previews

Engine data for the Fuji 498cc platform lists a compression ratio of 10.2:1 with a service limit for compression pressure. Torque values are provided for major engine fasteners, including cylinder head bolts and crankshaft nuts, in both ft-lbs and Nm.

• Intake valve clearance for the 500 H.O. is documented at 0.006” (0.15 mm) in the engine specification tables.
• The radiator cap relief pressure is documented at 13 PSI (89.6 kpa) for both carbureted and EFI variants.
• Alternator output for the fuel-injected Forest Tractor 500 EFI is specified at 350 watts @ 5000 RPM.

An official 438-page Polaris OEM workshop manual covering the 2012–2013 Sportsman 400 H.O., 500 H.O., and EFI Forest Tractor series, documenting engine, chassis, and electrical specifications for the entire 2012–2013 production build.